HOW TO install Z06 rear brake ducts
Here's how to upgrade your C5 with functional Z06 rear brake ducts. Thanks to Ray Wells (LV_2_XLR8 on the Corvette Forum) for these instructions and pictures! A Z06 rear brake duct kit was acquired from West Coast Corvettes and included everything except new rubber damper strips. You can transfer the rubber damper strips with the adhesive still intact. You get the left and right fender wells, ducts and facia grills - all GM parts - for under $300.
You need to jack the car up and remove the rear wheels. 97vette.com has jacking instructions here.
Remove the eight 9/32" screws retaining each rear fender
well to the car, including one that's not obvious - located under the
rocker panel. Notice the new fenderwell (left) comes with a section cut-out to
allow the duct to pass through it, to reach the rear brakes. If your C5 is equipped with them, the rubber
dampening pieces will need to be transferred from the old to the new
fender wells. Also, there is a clip on the fore-most mounting hole (the
one that goes under the rocker panel) on the old fender well that needs
to be transferred to the new one, as you can see in the photo.
The pieces lift off easily.
Next, mask off the area behind the door that will be modified for the opening. The masking tape will prevent you from damaging nearby paint and allow you to mark the area before cutting.
Next, take the template that came with the kit and mark the duct hole and the 4 stud holes. The author stated that the template that came with the kit was made of manilla folder-type material. He created sturdier templates from the one that came from the kit.
Drill two 1/2 inch holes at each end of the duct opening as close to the pen line as possible. Place some duct tape on the bottom of a sabre or jig saw and cut along the line. Using a fine tooth blade designed to cut metal will take longer but will leave a smoother cut.
With the cut made, you are now ready to mount the
duct facias. Be sure to remove the road dirt and debris, that is now
accessable, from the inside of the rocker panel.
After you complete drilling and cutting, remove the masking tape. Then, place the duct facia into the hole, rear first, aligning the rear stud and the lower stud with their holes. Next, tightly grip the duct facia and apply pressure until the other studs align into their respective holes. Push the assembly in until it seats firmly against the body. Place the flat washers and 5/16" nuts that come with the kit onto the studs, and tighten. It is recommended that lock washers are also purchased and installed in order to prevent vibrations from loosening these mounting nuts.
Slide the included duct through the cutout in the fender well and guide the duct over to the inside of the facia while you force the fender well into the opening. There is a bracket on the duct that is fastened to an already existing fender well hole. Screw the fender wells into position and install the rear wheels.
Here's the finished product, with functional Z06 rear ducts installed. This job takes approximately 4 hours, including several beer breaks. However, the author recommends that you only break for beer AFTER you do the cutting. :-)
Disclaimer: 97vette.com offers the C5 HOW TO section as a guide.
97vette.com will not accept any responsibility if you make a mistake and
damage your Corvette. You assume any and all responsibility to use caution
when performing work on your Corvette to prevent yourself from causing any